TPM in Industrial Canteen

A Journey of Change initiated at

Guwahati Refinery
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•Fortune 500 company

•Ranked 98th /only Indian company in the first

100 of fortune 500 .

•Largest Refiner of the country

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CORE VALUES

Care
Innovation
Passion
Trust
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GUWAHATI REFINERY ……….INDIANOIL

First Public Sector Refinery in India

Dedicated to the nation on 1st Jan, 1962
A 49 years old Refinery
Tucked away in the north east corner
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OFFICE TPM

IN

HR / CANTEEN
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 TOTAL PRODUCTIVE MAINTENANCE
( TPM )

Holistic productivity improvement

system

Drives
The entire factory and work force

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 CONCEPTUALIZATION AND
IMPLEMENTATION OF OTPM

Conference Hall
TPM
HR Facilitator

Guest House Canteen

Knowledge and
Implementation
Cycle
HR
HR Hall

Implementation
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 OFFICE TPM

Aims at improving Office

efficiency, productivity
and reduce Time losses in
Office processes and
procedures

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 THE FIVE PILLAR APPROACH

OTPM follows a Five Pillar approach from

conceptualization to implementation :

JH – Jishu Hozen
KK – Kobetsu Kaizen
E&T- Education &Training
PM - Planned Maintenance
SHE – Safety, Health and Environment

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THE OFFICE OF 2007

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Our Workplaces Looked Like This
 APPROACH ADOPTED THROUGH 5 ‘S’

Segregation of useful / wasteful records and documentation

Thoroughly cleaned tables, drawers and cabinets

Elimination of unnecessary documents

Indexation of all documents / files

Pre-fixed locations on tables / drawers / storage units

Creating a master record for all files & documents

Easy locating devices for the documents

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EMPLOYEE ACCEPTANCE………..EMPLOYEE INVOLVEMENT

SORTING…WEEDING
….. AND CLEARING

Initial 8 / 10 months

10 truckloads sorted out 12

NEW OFFICE INFRASTRUCTURE - NEW AMBIENCE

Conceptualized By Employees

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FILING SYSTEMS WITH VISUAL MANAGEMENT

BEFORE AFTER

File cabinet in office hall Right thing at right place 14

FILE SYSTEM WITH COLOUR CODING AND INDEX
More than 5000 files in HR Dept

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Visual Management
 FILE SEGREGATION AND FILE INDEX

File Index

Ownership
Indicator

Visual Management 16
MASTER COLOR CODING AND LOCATION INDICATOR

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Visual Management
INNOVATION : STANDARDIZED SHEET CODING
Document Retrieval Time Achieved : 30 – 35 seconds

Page Code

Name of the Department Subject Area Sheet Number

HR / SDU / 01 / HBA / 003 / 024

SDU/ Compactor SDU Sl No. File Number

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PHASE WISE REDUCTION IN FILE RETRIEVAL TIME

Better

M
I
N
U
T
E
S

YEAR

Document retrieval < 35 seconds

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 DESIGNATED PLACE FOR EVERYTHING

Ownership Labels Office Table Stationary Drawer20

DAILY MAINTENANCE CHECKLIST

Maintained On Rotation by HR Staff

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 SEATING LAYOUT CHARTS

Employee seat Locations with

Employee Photographs

Workstation Wise Employee

Seating and Job Areas

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 ELIMINATION OF NVA

25 processes, 30% Saving achieved in Response 23

Time
 HR HALL DISPLAY

List Index For Files In SDU

Rack wise – Number wise

Office Equipment Ownership

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 Efficiency Indicator

• Records incoming/outgoing
HR applications

• Average Response time

calculated and indicated
every week

• HR efficiency evaluated and

available on display

Response time Indicator

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 TPM AT REFINERY

OVERVIEW OF TPM AT GUWAHATI REFINERY 26

TPM AT GR REFINERY

PH - OMS 27
Why Canteen ???

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 WHY CANTEEN ?

Employee Satisfaction Index On HR Services

2007 Scope for

Improvement
59 %

Delightful 41 %

Services Dissatisfaction Index on

Canteen services
Others
40%

Parameters of Services
Canteen
Services
Establishment, Loans & Advances, Canteen
60 %
Services, Guest House, Administration, Event
Management, Furniture and Office Maintenance
Post Retirement Services

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 HR Goals - 2008

 Systematically reduce Response Time

 √ Develop /Turnaround Canteen into a Model Industrial Canteen

 Strive for Employee Delight in all HR services

 Identify and Remove Non Value Added Services in all areas

 Computerize HR work processes for reducing processing time

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 No tracking/planning
For Grocery
Procurement
Improper Storage of Individual Work
Materials/Food Stuff Style-No system
approach

Canteen Of
Improper waste
Disposal
2007 Poor ambience in
offices / storeroom

Poor Hygiene
Average Food Quality
And cleanliness
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OUR CANTEEN HALL OF 2007

Dull, Ordinary, and non vibrant

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 THE STORY BEFORE TPM…

No system for No means of tracking the

storing Grocery! Grocery levels!
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 THE STORY BEFORE TPM…

No means of food Customer

waste disposal! Dissatisfaction 34
 ENHANCE CUSTOMER
SATISFACTION
Ownership Systems
For Improve Food Quality
Maintenance/Upkeep

Improve OBJECTIVES Organic Waste

Ambience and Hygiene Identified Disposal

Automation for
Introduce Grocery
Customer Delight
Tracking Systems

Systematic Documentation
of Office Records

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 THE FOCUS OF ALL NEW EFFORTS

Change...Change...
Change…….

Ideas

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 A NEW VISION

Ordinary Unique/Ambient
Industrial
Workmen Canteen
Of High
Canteen standards

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8 PILLAR APPROACH INITIATED

Autonomous Maintenance

Focused Improvement

Planned Maintenance

Quality Maintenance

Early Management

Safety, Health & Environment

Education & Training

OTPM
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AUTONOMOUS MAINTENANCE

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 Kitchen Equipments
OWC

Burners

POTATO
ROTI MAKER PEELER

STEAM
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Boiler
 AUTONOMOUS MAINTENANCE

SOP for OWC & Checklist for maintaining all Maintenance of Automatic Rotimaker
the equipments in Kitchen. through Checklist

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FOCUSED IMPROVEMENT

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 FOCUSED IMPROVEMENT FOR FOOD WASTE
DISPOSAL
OWC

Surrounding areas getting littered by canteen waste, foul smell, no daily

clearance by Civil Contractor, dependence on outside agencies

OPTIONS :
• Tie up with PWD
•Have own system

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 RECYCLING ORGANIC FOOD WASTE

Collection of Organic Food waste from

Canteen daily

Removal of steel, glass and plastic

particles/items from the waste

Shredding the bigger hard items like bones,

lemon pieces etc into the shredder

Grinding the remaining waste into the OWC

along with saw dust and chemicals

Culturing the processed waste into manure

through the pruning system in 10 days.

Using the manure in cultivation of plants in

and around refinery.

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 RECYCLING ORGANIC FOOD WASTE

The manure prepared from OWC is used in the refinery and

township garden 45
KAIZEN FOR RECYCLING ORGANIC FOOD WASTE

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FOCUSED IMPROVEMENT

Earlier Storage Systems

• Old closed vessel

Storage for grocery

• No means to clean inside

• Materials get drawn

from top regularly

• No means to track
consumption levels

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 Focussed Improvement

Transition

Phase 1 Phase 2

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 FOCUSED IMPROVEMENT

Pondering on challenging assignment posed by

Japanese auditors

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 FOCUSED IMPROVEMENT

Idea of new vessel with transparent strip / Bottom valve

Why Not POKA YOKE ?

(mistake Proofing) 50
 DESIGNED BY TPM CIRCLE EMPLOYEES

Transparent Strip introduced for

Grain level visibility without

opening lid cover

Bottom Opener for Drawing out

Material – FIFO Concept

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FOCUSED IMPROVEMENT

FIFO System For Grocery

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PLANNED MAINTENANCE

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 PLANNED MAINTENANCE

Daily Check listing for Maintaining, Grocery Room, Kitchen,

Grocery Level, Main Hall 54
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MAINTENANCE OF AUTOMATIC ROTI MAKER (ARM)

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MAINTENANCE OF ORGANIC WASTE CONVERTER (OWC)

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 REGULAR MAINTENANCE THROUGH CHECKLISTING

Regular Monitoring of Checklist by Senior Officer.

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QUALITY MAINTENANCE

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QM – Display of Brands Of Raw Materials Used

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QUALITY MAINTENANCE

Weekly inspection by Nutritionists

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 QUALITY MAINTENANCE

Surprise Inspection by Canteen Committee

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 SERVICE QUALITY MAINTENANCE

Introduction of a Suggestion Book

Collect feedback on Food,

Ambience and Hygiene Conditions
daily

Review the Suggestion at the end

of each day

Take action on immediate

problems

Take up critical suggestion in

weekly meeting

Implement improvement in the

service
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EARLY MANAGEMENT

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 EARLY MANAGEMENT

Learning From Experience

 To Learn from Guwahati experiences , HR Heads Meet of all IOCL

Refineries held in September’10
 GR Canteen benchmarked for Display, Storage and SHE systems

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 EARLY MANAGEMENT

HR Heads of Other Refineries having on spot experience

Of change

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SAFETY, HEALTH & ENVIRONMENT

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 SAFETY

Disinfecting and Pest Control

Safety gloves, shoes, mask and apron

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 SAFETY

Cooks working in Kitchen and a boy serving food to guests

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INPUTS ON HEALTH/HYGIENE

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 HEALTH

BMI Measurement in Canteen Hall 70

Pictorial Charts on Health/Nutrition in Canteen Hall 71 71
ELECTRONIC SCROLLER ON HEALTH/
NUTRITION TIPS

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SHE : CARE FOR ENVIRONMENT

Treats Organic Waste (Food Left

Over, Raw Vegetables etc.) 60-70
KG of waste per day into Manure
Eco friendly treatment
Manure is used in Public Flower
Parks and Nurseries in and around
Refinery campus.

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EDUCATION & TRAINING

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 EDUCATION AND TRAINING

TYPES OF TRAINING
In house Training
Sponsored Training outside Refinery

•TRAINING PROGRAMMES

Soft Skills training by Hotel Management faculty

twice in a year with practical classes

Safety training by F&S dept every 6 months.

Training by Nutritionists on preparing healthy

balanced food.
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SOFT SKILLS INPUTS BY HOSPITALITY EXPERTS

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ONE POINT LESSON

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OFFICE TPM

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OTPM - RE-ORDER LEVEL IN GROCERY MANAGEMENT
MATERIAL RE-ORDER LEVEL CHART

SUFFICIENT
STOCK
RE-ORDER
Green Colour

Yellow Colour
LEVEL
CRITICAL

Red Colour
STOCK

Material Re-Order Level is defined and indicated in each

storage vessel/rack for proper tracking 79
 Office and Storage

A place for everything and everything in its place

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 Visuals

Planning & Scheduling Standardization

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 Color Codes For Lights , fans and Fittings
in Hall

Color Code Identity Chart

For Using → Switches in

Canteen Hall

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 CHECKLISTING & OWNERSHIP

Checklist for maintaining Plant

Grocery Room Ownership indicator
Canteen

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OTPM : RE-ORDER LEVEL IN GROCERY MANAGEMENT

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OTPM : RE-ORDER LEVEL IN GROCERY MANAGEMENT

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OTPM : IMPROVED GROCERY MANAGEMENT

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 ONLINE MEAL BOOKING SYSTEM

•Better Planning
•Less Food
Wastage
•Cost Monitoring

Electronic Kiosk

Intranet Card Reader 87

Participation In TPM Competitions

Winning TPM awards by Canteen Team

A Routine Affair

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 The Winning Team
We Own And Proudly Maintain

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WHAT DID WE ACHIEVE ?

An Industrial Canteen

With a
Difference

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CLEAN AND PLEASANT AMBIENCE

Turnaround ………Industrial Canteen 2011 91

A PLACE FOR ENJOYABLE MEALS FOR ALL

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A CURIOUS PLACE FOR VISIT BY
CHAIRMAN/VIPS/DIRECTORS

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REGULAR STREAM OF VIPS

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REGULAR STREAM OF VIPS

JIPM Team Visit at Canteen in Jan 2010

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 VIP VISITS

Our proud Team with JIPM Team including Prof Yoshio Tanaka San, Mr Kinjiro
Nakano
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 TURAROUND ON CANTEEN SERVICES

Satisfaction Index

2011
2007

30% 25%
Delighful Delightful
Services Services
Scope for Scope for
70% Improvement Improvement
75%

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 MISSION OF CANTEEN STAFF
Consistently Strive and Innovate For

Providing Hygienic, Quality Food in Ambient Environment

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 PERIODIC CUSTOMER FEEDBACK

Quality Of Services
assessed every Six
Months Areas For
Improvement
Displayed in Chart in
Hall

99
 They came, saw and Wrote

“Impressed by the cleanliness and orderliness of Canteen.

Other organizations in the city must take lessons from
them.”
- N. I. Laskar, Executive Editor, Eastern Chronicle

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They Continue to write…

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 Proud To Compare

Refinery Industrial Canteen A Mc Donald’s Outlet

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WAY FORWARD

Sustenance
And
More New Interventions

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 WAY FORWARD

Team Canteen

Strive for Consistent Improvement

Win The TPM Sustenance award - 2012
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